April 5, 2012 by Owen Geiger
Top view of double pallet wall with post and beam frame
Wooden shipping pallets are typically available for free and are very practical for building homes, furniture and many other things. We’ve already explored several ways of building pallet walls: Post and Beam Pallet Wall, Earth Lodge Pallet Walls, Interior Pallet Walls, Straw Bale Pallet Walls.
This new design sprang from the idea of creating wider pallet walls to provide space for extra straw/clay insulation or other type of insulation. Total wall thickness is about 16” not including plaster and/or wall cladding. Note how the good side (top side) of pallets all face outward. The building process is as follows:
1. Construct the post and beam frame. In this proposed design, the posts are spaced two pallets apart.
2. Build the interior pallet wall. Horizontal 2×4 or 2×6 plates are attached at the base, between courses of pallets and along the top. Plates could be 3’-4’ salvaged boards from broken pallets.
3. Add a spacer board between the pallet walls to help stabilize the wall. This could consist of short pieces of scrap blocking or a long board.
4. Build the exterior pallet wall so the outer surface aligns with the outside of the posts. Some partial pallets are required. Partial pallets could be cut from damaged pallets.
5. Mix and stuff straw/clay inside the pallet wall.
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